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AFIT/GAE/ENY/07-S02
The views expressed in this thesis are those of the author and do not reflect the official policy or position of the United States Air Force, Department of Defense, or the United States Government.
AFIT/GAE/ENY/07-S02
FINITE ELEMENT ANALYSIS OF LAMB WAVES ACTING WITHIN A THIN ALUMINUM PLATE
THESIS Presented to the Faculty Department of Aeronautical and Astronautical Engineering Graduate School of Engineering and Management Air Force Institute of Technology Air University Air Education and Training Command In Partial Fulfillment of the Requirements for the Degree of Master of Science in Aeronautical Engineering
September 2007
AFIT/GAE/ENY/07-S02
FINITE ELEMENT ANALYSIS OF LAMB WAVES ACTING WITHIN A THIN ALUMINUM PLATE
Approved:
____________________________________ Dr. Anthony N. Palazotto Chairman ____________________________________ Dr. Charles Leakeas Committee Member ____________________________________ Maj. Eric Swenson Committee Member
AFIT/GAE/ENY/07-S02
Abstract Structural health monitoring (SHM) is an emerging technology that can be used to identify, locate and quantify structural damages before failure. Among SHM techniques, Lamb waves have become widely used since they can cover large areas from one single location. Due to the development of various structural simulation programs, there is increasing interest in whether SHM data obtained from the simulation can be verified by experimentation. The objective of this thesis is to determine Lamb wave responses using SHM models in ABAQUS CAE (a Finite Element Analysis (FEA) program). These results are then compared to experimental results and theoretical predictions under isothermal and thermal gradient conditions in order to assess the sensitivity of piezo-generated Lamb wave propagation. Simulations of isothermal tests are conducted over a temperature range of 0-190F with 100kHz and 300kHz excitation signal frequencies. The changes in temperature-dependent material properties are correlated to measurable differences in the response signals waveform and propagation speed. An analysis of the simulated signal response data demonstrated that elevated temperatures delay wave propagation, although the delays are minimal at the temperatures tested in this study. In addition, a varying temperature gradient ranging from 75F to 281F is experimentally developed prior to actuating a pulse. It is observed that a plate bow occurred which indicated a thermal stress build up in the specimen through the thickness prior to a steady state condition. This condition is numerically evaluated and, at specific initial times, varying through the thickness stress that is due to gradual thermal flow is analyzed. Asymmetric thermal stress through the thickness of the thin specimen could possibly create geometric instability due to the development of a bending moment.
AFIT/GAE/ENY/07-S02
Acknowledgements I would like to thank Dr. Anthony Palazotto for his endless support and dedication in the role of my thesis advisor over the past two years. I have learned many things from him, not least of which is a scholarly attitude. I would also like to acknowledge the members of my committee Dr. Charles Leakeas and Major Eric Swenson, for their valuable insight and feedback. I would also like to thank Steven Olson, Jennifer Andrews, and Robert Brockman for their continual assistance and support and Mark Derriso for his sponsorship. Finally, I thank my mother, my lovely son, and all of my American friends. Their existence and expectations gave me the motivation and impowerment to proceed.
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ABSTRACT ACKNOWLEDGEMENTS LIST OF FIGURES LIST OF TABLES LIST OF SYMBOLS CHAPTER 1 INTRODUCTION 1.1 MOTIVATION: STRUCTURAL HEALTH MONITORING 1.1.1 Active and Passive SHM 1.1.2 Vibration Approach versus Wave Propagation Approach 1.1.3 Pitch-Catch and Pulse-Echo Techniques 1.2 PIEZOELECTRIC TRANSDUCER 1.3 ELASTIC WAVES 1.4 PREVIOUS STUDIES 1.4.1 Lamb Waves for the Long Range Inspection 1.4.2 Lamb Wave Propagation 1.4.3 Lamb Wave Scanning Approach 1.4.4 Defect Detection Using Guided Waves 1.4.5 Efficient Lamb Modes for Detecting Defects 1.4.6 Detection of Kissing Bonds by Lamb Waves 1.4.7 Temperature Influences on Wave Propagation 1.5 RESEARCH OBJECTIVE CHAPTER 2 THEORY vii
V VI X XIII XIV 1 1 1 2 2 3 4 6 6 6 6 7 7 7 7 8 9
2.1 ELASTIC WAVE PROPAGATION 2.2 LAMB WAVE IN THE FREE PLATE 2.2.1 Solution of the Free Plate Problem by the Method of Potential 2.3 PHASE VELOCITY( c p ) AND GROUP VELOCITY( cg ) 2.4 LAMB WAVE MODES 2.5 THERMAL THEORY
9 11 12 19 22 25
25
2.5.2 Relationship between Temperature and the Wave Phase and Group Velocities 32
CHAPTER 3 MODEL DEVELOPMENT 3.1 MODELING 33 33
3.1.1 Modeling of Specimen I for Isothermal Testing 3.1.2 Modeling of Specimen III for Thermal Gradient Testing
3.2 MATERIAL PROPERTIES OF 2024-T3 ALUMINUM 3.3 DETERMINING ELEMENT EDGE LENGTH ( Le ) OF FE MODELS 3.4 CALCULATING TIME STEP ( t ) 3.5 FIVE AND A HALF CYCLE HANNIN-WINDOW EXCITATION SIGNAL 3.6 DETERMINING THE SENSOR RESULTS 3.7 CONVERGENCE STUDY CHAPTER 4 RESULTS AND DISCUSSION 4.1 ISOTHERMAL TESTING OF THE SPECIMEN I
33 34
38 41 42 43 47 51 52 52
52
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60
65
65 72
80 83
APPENDIX B: THERMAL GRADIENT SIMULATION WITHIN ABAQUS CAE 100 APPENDIX C: MATLAB CODE APPENDIX D: SAMPLES OF THE DATA FILES BIBLIOGRAPHY VITA 128 139 143 145
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List of Figures Page FIGURE 1: TRANSVERSE AND LONGITUDINAL WAVES(4)....10 FIGURE 2: FREE PLATE GEOMETRY.......11 FIGURE 3: SYMMETRIC AND ASYMMETRIC PARTICLE MOTION ACROSS THE PLATE THICKNESS(10)..........17 FIGURE 4: THEORETICAL GROUP VELOCITY DISPERSION CURVES FOR AN ALUMINUM PLATE(4).....24 FIGURE 5: LAMB WAVE MODES OF THE RESPONSE.......24 FIGURE 6: THERMAL STRESS GENERATION DUE TO NONUNIFORM HEATING(25)....26 FIGURE 7: NONUNIFORM HEATING IN 1-D MODEL..........26 FIGURE 8: NONUNIFORM HEATING IN 2-D MODEL......27 FIGURE 9: DIFFERENT TEMPERATURE OF THE TWO SEGMENTS IN THE MODEL.......30 FIGURE 10: THERMAL STRESS FIELD, (a) : X , (b) : Y THROUGH THE THICKNESS ....30 FIGURE 11: PLOT OF X THROUGH THE THICKNESS....31 FIGURE 12: PLOT OF Y THROUGH THE THICKNESS....31 FIGURE 13: ALUMINUM MODULUS OF ELASTICITY VARYING WITH TEMPERATURE .....32 FIGURE 14: SCHEMATIC OF THE ALUMINUM SHEET SPECIMEN FOR ISOTHERMAL TESTING...34 FIGURE 15: SCHEMATIC OF THE ALUMINUM SHEET SPECIMEN FOR THERMAL GRADIENT TESTING........35 FIGURE 16: INFRARED IMAGE(4)...36
FIGURE 17: SPECIMEN III THERMAL GRADIENT PROFILES USING 10 THERMOCOUPLES..37 FIGURE 18: MIL-HDBK-5J(7)....39 FIGURE 19: 5 CYCLE HANNING-WINDOW EXCITATION SIGNALS AT 100kHz.45 FIGURE 20: 5 CYCLE HANNING-WINDOW EXCITATION SIGNALS AT 200kHz.45 FIGURE 21: 5 CYCLE HANNING-WINDOW EXCITATION SIGNALS AT 300kHz.46 FIGURE 22: 5 CYCLE HANNING-WINDOW EXCITATION SIGNALS AT 500kHz.46 FIGURE 23 : MODELING OF THE ACTUATING AND SENSING TRANSDUCERS IN ABAQUS CAE...50 FIGURE 24 : COMPARISON OF S 0 RESPONSE IN CONVERGENCE STUDY.....51 FIGURE 25 : THE EXISTENCE OF THE MAGNETIC NOISE(4)..54 FIGURE 26: SPECIMEN I S 0 RESPONSE AT 100kHz (0F).55 FIGURE 27: SPECIMEN I S 0 RESPONSE AT 100kHz (25F)..56 FIGURE 28: SPECIMEN I S 0 RESPONSE AT 100kHz (50F) .....56 FIGURE 29: SPECIMEN I S 0 RESPONSE AT 100kHz (75F)..57 FIGURE 30: SPECIMEN I S 0 RESPONSE AT 100kHz (100F) ..57 FIGURE 31: SPECIMEN I S 0 RESPONSE AT 100kHz (125F) ..58 FIGURE 32: SPECIMEN I S 0 RESPONSE AT 100kHz (150F) ..58 FIGURE 33: SPECIMEN I S 0 RESPONSE AT 100kHz (175F) ..59 FIGURE 34: SPECIMEN I S 0 RESPONSE AT 100kHz (190F) ..59 FIGURE 35: SPECIMEN I S 0 RESPONSE AT 300kHz (0F) ....62 FIGURE 36: SPECIMEN I S 0 RESPONSE AT 300kHz (50F) .62 FIGURE 37: SPECIMEN I S 0 RESPONSE AT 300kHz (100F) ..63
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FIGURE 38: SPECIMEN I S 0 RESPONSE AT 300kHz (125F) ..63 FIGURE 39: SPECIMEN I S 0 RESPONSE AT 300kHz (150F) ..64 FIGURE 40: SPECIMEN I S 0 RESPONSE AT 300kHz (175F) ..64 FIGURE 41: SPECIMEN I S 0 RESPONSE AT 300kHz (190F) ..65 FIGURE 42: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 1) AT 200kHz..68 FIGURE 43: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 2) AT 200kHz..68 FIGURE 44: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 3) AT 200kHz..69 FIGURE 45: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 1) AT 300kHz..69 FIGURE 46: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 2) AT 300kHz..70 FIGURE 47: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 3) AT 300kHz..70 FIGURE 48: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 1) AT 500kHz..71 FIGURE 49: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 2) AT 500kHz..71 FIGURE 50: SPECIMEN III S 0 RESPONSE COMPARISON(RM vs TG 3) AT 500kHz..72 FIGURE 51: HEAT TRANSFER FROM THE HEATING POINTS.74 FIGURE 52: TEMPERATURE FUNCTION AT THE HEATING POINTS....74 FIGURE 53: HEAT TRANSFER FROM THE ONE HEATING POINT THROUGH THE TIME .77 FIGURE 54: THERMAL STRESS FIELD, (a) : X , (b) : Y THROUGH THE THICKNESS .78 FIGURE 55: PLOT OF X THROUGH THE THICKNESS...79 FIGURE 56: PLOT OF Y THROUGH THE THICKNESS....79
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List of Tables Page TABLE 1: DIMENSION OF THE ALUMINUM SHEET SPECIMEN FOR ISOTHERMAL TESTING...34 TABLE 2: DIMENSION OF THE ALUMINUM SHEET SPECIMEN FOR THERMAL GRADIENT TESTING.35 TABLE 3: SPECIMEN III THERMAL GRADIENT PROFILES.......37 TABLE 4: UNIT CONVERSIONS OF THE BASIC 2024-T3 ALUMINUM PROPERTIES...39 TABLE 5: TEMPERATURE DEPENDENT PROPERTIES OF THE 2024-T3 ALUMINUM.40 TABLE 6: DURATION OF 5.5 CYCLE HANNING-WINDOW EXCITATION SIGNALS44 TABLE 7: FORMATION OF THE EXPERIMENTAL DATA FILE..49 TABLE 8: FORMATION OF THE SIMULATED DATA FILE.....49 TABLE 9: DATA FOR CONVERGENCE STUDY...51 TABLE 10: SPECIMEN I TOA OF S 0 RESPONSE AT 100kHz......55 TABLE 11: SPECIMEN I TOA OF S 0 RESPONSE AT 300kHz..61 TABLE 12: SPECIMEN III TOA OF S 0 RESPONSE.....67
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List of Symbols
Symbol
Explanation
A Amplitude
Ai Asymmetric modes cg Group velocity (m/s) cL Longitudinal wave speed (m/s)